This exclusive
trapezoidal cross section allows the formed foil to bond with
the flat interleaving when subjected to heat treating near
2000F for nearly 24 hours. This results in a very durable
assembly that is then coated. Triangular crimping would limit
the contact area and result in very weak bonding. Trapezoids
win!
High volume manufacturers
like to crimp and coat the material in a continuous process.
Some “manufacturers” buy rolls of coated material rather than
coat their own. The material is then wound or cut/stacked
into an element. This approach makes it impossible to bond
the layers together so a variety of pins have to be inserted
to provide strength. This ‘loose’ assembly is subject to
exhaust stream pulsations (one pulse per cylinder or one per
turbine blade) that can ablate the coatings.
Broken, contaminated,
worn out catalysts may be worth some cash! If you can
accumulate a few hundred pounds (about 5-6 elements) call PCA,
Inc. and we will arrange to pick up your old material, melt it
down and write you a check!
Catalysts are coated with
two types of coatings: 1) A wash coat that adheres to the
special stainless steel or ceramic foundation and 2) A
precious metals coat. The wash coats are available in many
chemistries…to enhance some particular aspect. Unfortunately,
there can be trade-offs. For instance an automotive grade is
meant to enhance NOx and/or CO destruction at the expense of
VOC performance. Precious metals coats can contain platinum,
rhodium, palladium and a number of other additives. Not only
do we purchase premium grade coatings and precious metals, we
specially process them before we use them to enhance
performance. This is why ADCAT™ catalysts usually offer
better performance, size for size, than other brands
The main point is that
there is no industry standard for terms such as “industrial”
“residential”, “critical”, “hospital” or “super-hospital”
grade to allow comparisons between manufacturers. The best
way to compare is to obtain the attenuation curves for the
units. If a local permitting authority places requirements on
a site, then a consultant can generate proper limits in dBA at
particular distances from the equipment. Contact PCA for your
sound attenuation needs and we can discuss the necessary
details.
PCA offers two lines of
mufflers, industrial grade and OEM grade for large stationary
engines. Available in different performance levels and styles,
these mufflers offer solid construction, come with prime coat
high heat paint and provide value-based sound control.
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